Architecturally finished complete building envelope system

ABSTRACT

A cementitious building having a predetermined measured grid system using structural trim members for doors and windows that are sized so that when installed in openings no further trim is necessary.

This application claims the benefit of U.S. provisional application 61/793,918 filed Mar. 15, 2013 and is a continuation-in-part of U.S. patent application Ser. No. 11/982,455 filed Oct. 31, 2007, which is a continuation-in-part of U.S. patent application Ser. No. 11/123,635 filed May 6, 2005, which is a continuation-in-part of U.S. patent application Ser. No. 10/201,035 filed Jul. 23, 2002, now U.S. Pat. No. 7,204,060, which is a continuation-in-part of U.S. patent application Ser. No. 09/784,848 filed Feb. 16, 2001, now abandoned, and a continuation-in-part of U.S. patent application Ser. No. 09/741,787 filed Dec. 21, 2000, now abandoned, which claimed the benefit of U.S. provisional application 60/183,472 filed Feb. 18, 2000, now expired, the disclosures of which patent and patent applications are incorporated by reference as if fully set forth herein.

BACKGROUND OF THE INVENTION

This invention's product and processes of manufacturing and construction are for creating uniform cementitious units for a component system that when designed and employed in a uniform grid result in an environmentally friendly, cost effective and energy efficient habitat that is fire proof, termite proof, mold proof and nondecaying with minimal VOCs. The invention's methodologies and processes of manufacturing employ factory applied wall coatings (“liquid sheetrock”) on the interior surface for replacing sheetrock and on the exterior surface the factory formed, integral, architecturally finished surface result in a structural component that facilitates mechanical requirements and requires no further interior nor exterior finishing. The present invention's completely finished weatherproof components install in a one step on site system superior to factory manufacturing systems.

As all languages evolve and improve, to avoid confusion of what mold is being referenced in the numerous cites in this teaching of present invention the use of British English, Australian and Canadian word “mold” refers to architectural features and the English word mold refers to the bacteria.

Wood has been the standard building material for centuries. But now due to the demand for human habitats outstripping the earth's natural ability to meet the need, as eco-ecology experts teach, the result is lower quality and increased prices for wood habitats. There is a construction material developed in Europe in 1920's called Autoclaved Aerated Concrete (“AAC”). In Europe AAC is a popular building material. AAC is a building code and UL listed product. USA needs cementitious building products, like AAC, due to deforestation and global warming. Regrettably the reason AAC has not been accepted is AAC has not been economically competitive due to additional labor and material required. This invention transforms cementitious products into an accepted standard construction material and is a continuation in the goal to make possible environmentally friendly habitats that are structurally superior and cost competitive compared to other materials and systems.

1. CGS Computerized Grid System Coordinated Wall and Roof Design Automatically

Over the millennia humans have had various processes for constructing habitats in relation to the finished product. There is a Biblical record that in approximately 1,000 BC King Solomon built the temple for God by purposefully cutting and architecturally finishing stones in the quarry, away from site, and then bringing the finished stones to the site where the stones were installed. Many modern day construction systems use secondary factories to construct components, and even entire habitats that are then transported and installed at the site.

In our modern society there is a strong need for a computerized dimensional grid system that can efficiently coordinate the design of aesthetic habitats while simultaneously giving accurate component and reduced cost estimates in a simplified manner while increasing legal American citizen workers' pay and benefits with the resultant being a superior structural habitat that is environmentally smart.

Construction of habitats in part or whole in factories and then transporting them to the site has evolved due to the advantages of materials being protected from damage and labor delays due to inclement weather, storage for less waste, labor stream lining. The problem with secondary factories to construct components is the great additional cost involved in constructing a secondary assembly factory, the costs in transporting the units to the site, and the weather can still cause delays on site. There are books on the subject of cost effective construction written by experts who advise the use of nominal sized lumber in an optimal 2′ grid system. Wall studs are available in a length so that when the bottom plate and double top plate are added the height equals a standard 8′ piece of sheetrock. But no one has developed a complete component construction system from floor to roof that has great flexibility for custom floor plans and is aesthetically pleasing architecturally. Therefore a strong need exists for a healthy, superior product that can be quickly designed via a computerized grid system that increases pay and benefits for legal US citizens while cost effectively constructed.

2. Liquid Sheetrock

Over the history of constructing habitats various wall coatings have been applied to wood and stone. In the early 1900's century residential construction in the USA used a plaster applied to a wood lathe for interior walls. This system was replaced by sheetrock applied directly to wood studs. Sheetrock is labor intensive, has a great deal of waste and is susceptible to water damage and mold. Ideally there needs be a climate resistant wall coating that is economical.

Conventional sheetrock is not weatherproof so it cannot be factory attached to components and transported in a manner that would expose it to rain. There have been many coatings for concrete developed, but there is a strong need for a product that has attributes needed for this invention to be compatible with AAC and compatible with existing sheetrock construction materials.

3. Processes and Products Architecturally Finished

AAC exterior walls required a labor intensive and costly thick stucco or wood furring with architectural features applied to wood furring. The additional materials deplete natural resources and cause habitats to have a higher embodied energy consumption and contribute to global earning and pollution. There are precast concrete pieces that have an architectural finished surfaces but precast concrete has minimal insulation value, is cumbersome heavy and basically impossible to modify.

4. Leveling Base Panel

Whether factory-built or built on site, the concrete slab and/or basement wall is the foundation for all subsequent work, yet their top surface inherently undulates due to the often ‘rough and tumble’ construction site and unavoidable element of human error in construction and finishing. The subsequent unleveled and undulating surface creates problems for subsequent conventional construction. But the imperfect slab's surface causes even more problems for AAC because AAC is dimensionally accurate to within ⅛″ of an inch with mortar joints of only 1/8″ and is not flexible.

As known in the art, conventional installation of AAC blocks is similar as to CMU. Comparably, conventional CMU has ¼″ mortar joints that allow for greater correction capacity to compensate for slab imperfections. The first course of no longer than 24″ long AAC blocks are individually placed and leveled. This is a very time consuming and labor intensive process. The first course requires waiting for mortar to cure before subsequent construction can continue because the first course must remain as level as possible. It is customary to wait a day before laying subsequent courses of block. Then the blocks would be routed for electrical, etc., and repaired or wood furring and sheetrock applied to interior walls. When panels are employed instead of blocks, the panels are installed vertically, but again the 24″ widths are affected by inherit uneven slab requiring each vertical panel to be plumbed, which is time consuming. The time factor in placing vertical panels is especially critical because cranes are employed which are very expensive to operate hourly. The Germans invented a machine that levels the base course of mortar.

5. Filler Wall Block & 6. Corner Wall Block

Conventional AAC construction installs AAC in alternating stacked blocks or expensive panels that create a great disparity of face deflections requiring expensive and labor intensive multiple coats of plaster to create a smooth surface.

The current art due to the solid nature of AAC requires the interior face to be routed for electrical and plumbing if the walls are not furred in and sheetrock applied to wood. Alternatively, the repaired routing and surface face deflections require plaster to be applied in a two layer application being built up to a minimum ⅜″ thick. The labor required to apply the plaster in several coats makes the cost equal to furred walls with sheetrock so the result is that current use of AAC is priced out of the market because it costs 30% more than the average home constructed of wood or CMU. What is needed is a construction system that reduces face deflection and retains a measured grid so minimizes the labor, time and cost of field cutting many individual pieces to custom match each plan.

7. Air Duct Crown Moulding

AAC historically has had problems with being a solid material that inhibits installation of mechanical air ductwork that is usually hidden in unfinished areas of wood frame construction. These unfinished areas result in wasted unlivable areas. Such areas, like attics, are not insulated and thereby cause air supply ducts to loose effectiveness as they travel distances to supply temperature desired air to insulated areas. Current art AAC has wood roofs and attic areas or costly and time consuming dropped ceilings, etc. Present invention employs either the 2″ air chases and/or architecturally finished insulated crown molding that has 2″ ducts inside.

8. New Mold Pattern for Precast Slab

Precast concrete panels that are used for floors and ceilings have the problem of the underneath joint not being able to be finished due to its design of a curved base. The result is an unfinished ceiling surface requiring additional finishes or dropped ceiling, or, the contemporary exposed and simply spray painted warehouse look.

There are many waterproof coatings that are not vapor permeable and therefore cannot be used for concrete products because cementious products must be vapor permeable so the moisture in the concrete can escape. If the moisture does not escape it can cause condensation on interior surface and that leads to damages and mold. The present invention allows for a 2″ thick section of closed cell spray insulation to be sandwiched between two panels of AAC, the interior panel 6″ thick and the exterior panel being 2″ thick. The sandwiching creates an unanticipated exponential increase to thermal values as compared to foam insulation on the inside or outside surfaces. Also are the benefits from exterior architecturally featured AAC of fire resistance and protection from elements and creatures, etc.

Alternatively, the present invention has an architecturally featured foam panel that is applied with a zero VOC adhesive to the exterior surface of AAC and is coated on the architectural surface with colored coating so the resultant panels look like natural wood and stone but have superior insulating properties and less environmental negative impact. The energy savings and other advantages of foam insulation far surpass any negatives. Being factory installed, in the present invention's system, is also another advantage.

The present invention allows for entire walls of 8′+tall and 10′+long to be manufactured and shipped to site and then openings cut out as desired for doors and windows. This is unprecedented in present construction that requires vapor barrier house wraps, etc.

DESCRIPTION OF THE PRIOR ART 1. CGS Computerized Grid System Coordinated wall and roof design that automatically adjusts.

Starting with the major construction practices, there are many examples of good factory construction systems to compare, but one of the most innovative is a whole-house construction system (U.S. Pat. No. 6,253,504 Cohen, et al. Jul. 3, 2001) wherein a complete factory is built in the subdivision, then entire house is built in the on site factory with the completed house being trucked within subdivision to individual lot and placed on foundation. The purpose of building a secondary factory wherein to assemble parts is to protect the materials and laborers adversely affected by inclement weather. This system requires a large subdivision of many homes to be cost effective and is not feasible with projects that have steep topography due to transporting the entire house and requires fairly good weather conditions for crane and workers to install house on foundation. Other factory manufactured homes constructed in units have sheetrock and must be protected from elements.

Wood frame and precast concrete habitats as well as other factory sized component design systems fail in maintaining adherence to the discipline of a grid design that is easily coordinated with a precast roof system that has zero waste as present invention teaches. They also lack flexibility, variety and uniqueness in architectural design without compromising the discipline of the dimensional grid system.

Computer software for framing and materials are common to the industry, but these prior art programs are inadequate because they require human input for each component and coordinating of various subcontractors and materials.

2. Liquid Sheetrock

Conventional AAC walls are furred in with wood stud walls cover with sheetrock or a thick ⅜″ two coat application of interior plaster. Sheetrock has susceptibility to mold and is permanently damaged when introduced to water. When there is a house fire sometimes the greatest damage done to a house is by the water used to extinguish the fire ruining the sheetrock, insulation and lumber. There are coatings for concrete for various functions such as water proof and fireproof, but none to replace the need for sheetrock by being of a composition that conventional sheetrock mud can adhere itself and can withstand the elements while in transit and installation in the field.

Prior art U.S. Pat. No. 6,682,617 Gregg, et al., is an AAC sheetrock that has better fire protection than standard sheetrock but has all the inherent disadvantages of sheetrock. U.S. Pat. No. 5,283,279 Hara et al. is for fire proof coating for cement and U.S. Pat. No. 4,614,755 Rodgers, Sep. 30, 1986 is for waterproofing cement objects, but neither have the composition of present invention that provides the additional attributes necessary to replace sheetrock for interior walls and ceilings. U.S. Pat. No. 5,599,634 Davies, Feb. 4, 1997 is basically a super thin self leveling concrete specifically to be applied to horizontal floors at a thickness no greater than “1 mm”, that is 0.0393701, or basically only 1/25 of an inch thin. This indeed is a neat feat for what is basically a super thin self leveling concrete, but the claim “durable” is relative in regard to being able to withstand normal wear from the abrasiveness of commercial foot traffic, but at least claiming such hardness as durable for a floor means that the required sanding of joint compound to finish seams would leave a noticeable difference in surface texture between this product and a sanded joint compound. The chemical composition is not as compatible as desired for good adhesion with sheetrock joint compound required for joints and touch up for a wall and ceiling application. None of the prior art coatings are compatible with conventional AAC construction due to being too thin and with the quick absorption rate of AAC would leave inevitable cracks, seams and uneven places when applied in sections over a large surface area. The alternative of conventional plaster that does create a smooth surface across a wall of varying deflection block faces is a labor intensive, multi coat, ⅜″ thick hand applied finish. What is needed is a product that is chemically and workability compatible with sheetrock joint compound, is smooth and can be applied while AAC is vertical, horizontal and even upside down for ceilings when needed.

3. Leveling Base Beam

One of the problems with conventional construction is the uneven and unlevelness of poured slabs on which walls are constructed. Prior art solved the inherent problem of uneven slab surface by removing the human element and employing a precast member in one fashion or another, whether precast footings, or entire wall sections. U.S. Pat. No. 4,142,340, Howard, shows a precast footing 12, that requires stairs to cross over and so is not a primary course, structural component of wall surface, positioned on a poured at site, human finished slab. U.S. Pat. No. 3,952,471 Mooney, shows a standard footing, 31, employing the problematic precast wall sections having windows already positioned so that no field relocating can be made.

4. Space Wall Block & 5. Corner Wall Block

Prior Art for wood and like material construction requires materials to be cut on site or the factory according to plan. Precast concrete construction does not allow for field modification as U.S. Pat. No. 5,761,862, Hendershot, et al, Jun. 9, 1998 shows the corners being a single component. Precast corner units cannot be made of AAC in current factories and the shipping challenges of a precast corner are more than flat panels being attached in field to make a corner. There is not a coordinated system that allows for a minimal number of components to construct an almost unlimited number of variations for architectural floor plans and elevations.

6. Process and Product of Architecturally Finished Exterior on AAC with Smooth Interior Surface

Prior art for AAC to make an architecturally finished exterior surface composed of any wood or wood like materials (i.e.: Hardi-Plank siding) require furring strips anchored into AAC and then wood siding and roofing attached to woods strips. AAC roof panels required decking or other mechanical means to attach conventional construction materials. This method of finishing the exterior surfaces of walls and roofs is not protected from delays in labor due to inclement weather, the multiple steps are labor and material intensive, and are susceptible to decay.

It is common in the current art to make architectural design features in standard precast concrete panels, but not for AAC. Standard precast concrete is extremely heavy and has very low insulation values. The current method of manufacturing AAC makes it impossible and impractical to manufacture grouped bulks of architecturally featured AAC panels due to need for AAC to foam/rise and be removed from mold, wire cut into dimensional material and then autoclaved. It is not cost effective to do this in a piece-by-piece process as standard precast.

7. Air Duct Crown Moulding

Prior art of large ducts for air condition and heating requires large open spaces and cavities that solid cementious habitats do not provide. What is needed is an improved manner to get heating and air conditioning supplies ductwork in habitats that have solid cementious walls and ceilings with no cavity areas.

8. New Mold Pattern for Precast Slab

Because most prior art habitats' exterior structural walls are usually composed of wood, precast concrete floor panels are prohibited by code because if there is a fire, then the inhabitants are crushed by the concrete panels when the walls fail due to burning. In commercial concrete buildings where precast concrete panels are used for floors and/or ceilings it is usual practice to hide the underside of the panels by installing acoustical ceilings, or cover with sheetrock or spray a popcorn ceiling texture that hides the imperfections. Additionally, due to the precast concrete's bottom edge's standard rounded edge design the joints cannot be finished with tape and mud as does sheetrock joints that have a smooth transition. Now the ceiling surfaces of AAC panels are able to have architectural patterns as desired.

Prior Art Conclusions

Therefore, all the prior art fails by employing valuable ecosystem resources that would be better left to their created purpose to transform the negative effects of a growing human population, have a higher embodied energy usage, resort to constructing expensive secondary factories so that the habitats that employ prior art materials and methodologies can be constructed in a more organized manner while protected from inclement weather. The few coatings for various uses over concrete were never conceived to be used with ACC walls and ceilings and are not ideally compatible with AAC nor sheetrock joint compound. The exterior architectural effects use materials that deplete the ecosystem's dwindling resources that better serve us undisturbed, create more pollution due to short lifecycle, are subject to fire, mold, decay, etc., are labor intensive and costly in both installation and maintenance.

BRIEF SUMMARY OF THE INVENTION

Throughout history humanity has the strong need for habitats. As our human population increases, so increases the demand for natural resources used to build habitats. As the human population continues to grow, it is proven that the material demand of required earth's resources to construct conventional habitats will outstrip the supply. Additionally, the increased burden of other negative effects imposed upon the earth's ecology, such as disproportionate carbon monoxide and global warming, demands that the habitats we humans build save trees and other valuable resources that transform and reverse the negative effects of carbon monoxide and global warming.

The advantages of the present invention of an extremely environmentally friendly habitat are being cost effective and meeting the human need for the best home of a habitat that is fire proof, termite proof, mold proof, nondecaying, and that is easily and economically constructed. The objects and teachings of this CIP make it possible for a crew of no more than five workers to construct a simpler house plan of a standard two story, 2,000 square foot house, even in light rain and mild winds, to be “dried in” and ready for trades in approximately three days. This is possible by using only materials that will not be damaged by rain or freezing during transport and installation. Because the present teaching does not use the components that cause most of the prior art's waste, the additional factory-type assembly line approach is no longer needed. Once the habitat is dried in, since most of the exterior is finished, the habitat becomes its own little factory protected from inclement weather. Therefore all trades can easily and cost effectively schedule and complete a house with no more waste than in a factory assembly line.

1. CGS Computerized Grid System Coordinated Wall and Roof Design that Automatically Computes as Designed and Can Be Used on Websites

One object of the present invention is the computer program for designing and estimating the finished component and grid design system. The Computerized Grid System (CGS) is user friendly. When someone is designing the floor plan, first the desired wall heights are chosen. Then, as the floor area is enlarged to the required grid criteria, the coordinated components automatically are computed. This allows for customers to visit a website and design a house and get a very accurate cost. For geographic location the person's zip code computes the variables, such as shipping cost index. Manufacturing and constructing weatherproof finished components executed within the discipline of the computerized grid system allows for construction in all but the most inclement weather thereby eliminating the need for expensive secondary factories used to assemble materials into a habitat.

2 Liquid Sheetrock

Another teaching of present invention is liquid sheetrock, a unique factory applied coating that provides a smooth face superior in appearance and performance to conventional sheetrock boards. It is has a much more even surface than alternative hand applied plaster. It is complimentary to AAC in that it is mold proof, fireproof, nondecaying and vapor permeable. Georgia State University has conducted a test on its mold proof and water resistance and determined it is “as mold proof as stainless steel.” The walls and liquid sheetrock can go through a New Orleans Katrina-type flooding and be submersed for two weeks and simply be washed off. The finish coat can be painted, is repairable and the unique chemical composition is compatible for joint compound to achieve good adhesion and can be sanded for adding small interior wood and sheetrock walls. Additional coats of sheetrock joint compound can be added for joints in a single coat without use of joint tape as is industry standard practice. The invention, liquid sheetrock for AAC, is a blend of dry ingredients composed of up to an approximate two parts Portland Cement, up to an approximate part calcium carbonate powder, up to an approximate part lime and up to an approximate part methylcellulose, and this dry composition is mixed in an approximate one-to-one ratio with a liquid solution that is composed of approximately one half water and one half methyl methacrylate emulsion. This mixture allows for a self-forming smooth surface that can be applied by trowel on a vertical surface and even upside down for ceilings. It cures quickly with the result of an even, smooth surface. When applied on the modular units that are described in U.S. Pat. No. 7,204,060. The result is a wall that requires no subsequent sheetrock or plaster work. When wall blocks are installed, the mortar in the seams is allowed to cure until in a firm state so there is no additional shrinkage. The joints are then scraped clean with an appropriate tool. Then a simple one coat of sheetrock compound is applied without the use of previously required joint tape, the seam then is lightly sanded and the walls can be finished with paint. The entire process for an interior wall finish is reduced to a labor and material saving single skin coat of joint compound on vertical seams.

The structural component and the liquid sheetrock are basically mold proof and emit no harmful gasses as do so many other products. Therefore, the interior air of habitat is as clean and healthy and even healthier than out door air in polluted cities with the assistance of quality air purifiers.

3. Process and Product of Architecturally Finished Exterior on AAC

With Smooth Finish on Interior by Employing A Mold.

Another teaching of present invention in this CIP application is the processes and product of an integral architectural features on the exterior surface of component units. The integral exterior architectural ornamentation is fireproof, termite proof, mold proof, nondecaying, insulating and requires minimal maintenance. The architectural ornamentation is very advantageous for both exterior walls and roof panels.

4. Leveling Base Panel

Another advantage of the present invention is a manufacturing process and construction methodology resultant in a product that is a load baring first course called a leveling base panel. Every system requires the site construction to begin on the slab and/or foundation. The leveling base panel allows immediate installation of subsequent construction upon it. The present invention allows for a single base course to be installed in minutes instead of hours painstaking leveling. Another advantage is that the subsequent construction is able to commence immediately instead of waiting hours so the first course can cure before putting weight on it. The house is designed in modular 2′ grid system so the leveling base panel can be cut in the factory, but also cut in the field for onsite modifications. The leveling base panel is architecturally finished and has an interior liquid sheetrock finish applied thereby eliminating several time consuming and costly steps in construction process. The architectural features are functional in that the architectural features are located at the top where there will be the mortar joint for subsequent course of wall block, as taught by the invention. Therefore the ⅛″ seam becomes invisible, again saving time and labor in finishing.

Because the leveling base panel teaches a utility chase incorporated therein, there is no need for further labor. Therefore, the advantages of the present invention are a leveling, structural and immediately load bearing, primary course of leveling base panels that incorporate architectural features which eliminate the need for further finishing and also incorporate a continuous utility chase system so the trades simply install their mechanical wires, piping, etc., requiring no further modifications. The invention's process of cutting out door openings and 45° corners into the leveling base panel after installation allows for greater accuracy, quicker installation, a consistent and precise leveling. Therefore, minimal waste pieces of cut out sections are easily and environmentally transformed to benefit the ecology.

5. Filler Wall Block

Another object of this invention is the filler wall block that is coordinated with the computerized grid system design, in this case employing the preferred 2′ grid, and how the dimensional non-architecturally finished wall block and casing blocks allow for aesthetically pleasing design variations without cutting or waste. At the end of the wall section that terminates at a perpendicular wall there is installed a filler wall block instead of a standard wall block. The filler wall block is a factory modified wall block that has its width reduced by the thickness of the wall it abuts so the 2′ grid is maintained. By employing only these two vertical block types, wall and filler, an entire habitat with a myriad of possible variations can be easily built and coordinated with the zero waste precast cementious roof system so the entire habitat has no waste in its vertical wall sections.

Another object of this invention is the filler wall block that is coordinated with the computerized grid system design, in this case employing the preferred 2′ grid, and how the dimensional non-architecturally finished wall block and casing blocks allow for aesthetically pleasing design variations without cutting or waste. At the end of wall section that terminates at a perpendicular wall there is installed a filler wall block instead of a standard wall block. The filler wall block is a wall block that has its width reduced by the thickness of the wall it abuts so the 2′ grid is maintained. By employing the primary three vertical block types (leveling base panel, wall block and top beam), the teachings of this invention of casing and space components enable an entire habitat to be easily built and coordinated with the zero waste precast cementious roof system so the entire habitat has almost no waste. The trimmings of the wall block are put through the invention's planer/molder machine and become window and door casing that is fireproof, termite proof, mold proof, nondecaying and insulating.

6. Corner Wall Block

Another alternative object of this invention is for when employing wall blocks that have manufactured architecturally finish on the exterior surface to make a continuous pattern on exterior of house requires 45° cuts on the vertical sides at outside corners so that the grid system, in this case on typical 2′ grid, allows for good architectural design variation. For inside corners the teaching of this invention corner block is employed. Thereby employing only these three vertical block types, wall, casing and corner, an entire habitat is easily built and coordinated with a precast cementious roof system that has zero waste.

Another object of this invention is when the architecturally finished wall blocks use a simulated siding design, it is necessary to replace vertically orientated wall blocks with this invention's horizontal wall blocks. Horizontal wall blocks are approximately 10′ long and have minimal reinforcing for transporting and erecting because their primary function requires compressive strength, not sheer strength. Since the horizontal blocks are employed within the present invention's “CGS” (computerized grid system), there is rarely waste as the 2′ incremental sections are easily installed at various places.

7. Air Duct Crown Molding

Another teaching of the present invention is the process and product of crown molding air ducts that are an alternative to the internal duct system formed within top beams as taught in U.S. Pat. No. 7,204,060. The air duct crown molding has an approximate 2″ diameter internal air duct channel that is compatible with requirements for high velocity forced air systems as known in the art. This invention enables an entire architecturally finished air duct system to be economically installed by a crew immediately after the habitat is dried in. The professional mechanical heating and air contractors simply connect the mechanical units to the crown ducts. Then, the supply vents are cut into the crown ducts in the desired size and location as specified by a mechanical engineer.

Another teaching of the present invention is a special modification to the edge pattern in molds used to manufacture precast concrete panels. By changing the industry standard bottom rounded edges to an edge that results in a design similar to the tapered edge of sheetrock boards and adding fast curing liquid sheetrock to the panel's bottom surface, the precast panels are able to be used for finished ceilings. The liquid sheetrock is applied while transporting the precast panel to storage by running the panel's bottom side over an applicator. The fast curing liquid sheetrock has cured adequately by the time the panel is put into storage.

8. New mold pattern for bottom edges of precast slabs and entire walls

By this invention, the result is an extremely environmentally friendly, structurally superior habitat that is fireproof, termite proof, mold proof, nondecaying, zeros VOC and insulating that is now able to be constructed and sold at a price that is economically affordable and competitive to all types of conventional construction. The evolution is to create entire walls at 8′ and 10′ tall and 20+′ long. The walls will have architectural features on the exterior and smooth on the interior with factory applied liquid sheetrock. The walls will be eventually composed of aerated concrete that have a chemical composition replacing the need for autoclaving and another invention of inventor using carbon fiber reinforcing to replace current steel reinforcing. The walls will be very strong and lightweight. The entire wall sections walls will be assembled on site and once erected the openings for doors and windows will be cut with tools in the field. The excessive material is inert and can be ground and become a soil enhancer so there is no off site waste.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIGS. 1 and 2 show a sample floor plan for the filler block components in the 2′ Computerized Grid System (“CGS”).

FIGS. 3 and 4 show a sample floor plan for the diagonal end corner block components in the 2′ CGS Computerized Grid System

FIGS. 5A-5E show the house and roof system now employing the teaching of present invention of 2′ CGS.

FIGS. 6, 7 and 8 show a single coat with brick and stone applied.

FIGS. 9, 10, 11 and 12 show the molding system for horizontal application of architectural envelope components of roof and walls.

FIGS. 13, 14, 15, 16 and 17 show the molding system for vertical application of architectural envelope components of the roof and walls.

FIGS. 18, 19, 20, 21 and 22 show the parts of a large wall section architectural envelope with an internal insulating foam manufacturing system.

FIGS. 23, 24, 25 and 26 show the insulated crown molding air duct system.

FIG. 27 depicts a section of the complete building.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 teaches the floor plan layout linear grid units 1 coordinated with filler block 2 components of the Computerized Grid System software program. The number of linear grid units 1 is the basis and over all factoring by calculating the number of grid units 1, whether horizontal or vertical, then multiplying the number of grid units by various components of the known teaching of a self-leveling base panel that has utility chase and contains only enough reinforcing to transport and install, the 6′ tall wall block, the header top panel that has continuous reinforcing sufficient to act as header for openings and the air duct system then subtracting the CGS grid area units 1 of the number and type of openings (door 3, window 4, etc.). This makes it is possible to accurately estimate the total number and type of components, labor time for construction, etc. of an entire structure including roof of FIG. 5B. The roofing component of tis application's teaching of invention CGS system employs the unique mathematical formula of complimentary angles and distances to automatically calculate all the changes of materials and labor for each grid unit increase or decrease.

In FIG. 1, filler blocks 2 are manufactured in factory 18″×72″ x various thicknesses, or in field as FIG. 2 shows how the filler blocks 2 are cut from wall blocks 6 and trim 7 is able to be made from a cutoff piece. At the front door area the habitat maintains the 2′ grid simply cutting one wall block 6 in half vertically and then use the two halves 8 to center the door and then simply add trim block 7. By employing only these three block types, wall, trim and square corner, on top of a leveling base panel, an entire habitat can be easily built and coordinated with a precast roof system FIG. 5B that has zero waste.

FIG. 3 teaches the floor plan layout linear grid units 1 coordinated with diagonal cut corner blocks 5 of the Computerized Grid System CGS software program. Wall block 6 and trim blocks 7 allow for good architectural design variation without cutting or waste. At the end of walls, when required, there are diagonally cut corner blocks 5. By employing only these three blocks and entire habitat can be easily coordinated with a precast roof system that has zero waste. The software program shows the CGS 2′ grids. At the front door area the habitat maintains the 2′ grid simply molding an edge of wall block 6 with trim block 7 to create opening blocks 9 that are a unique blocks to this invention so that the structural wall is also the door trim and chase system. By employing the teachings of present invention, only the three block types of wall, filler and corner block with architectural trim block on top of a self-leveling base panel, and then on them installing the top header panel (that has special reinforcing to act as a header and which removes the need for U-blocks and cast in place headers) the entire habitat can be easily built and coordinated with a precast floor and roof system that has zero waste as this invention teaches in 2′ CGS.

This unique construction methodology allows for entire wall sections to be erected and then the door openings cut out of the base panel. Simply securing a sheet of plastic by adhesive tape to the slab where the door openings are to be cut prior to mortar being applied allows the mortar and block to be easily removed when it is time to cut out the opening. When the inventions' teaching of trim blocks 7 are installed, the vertical longitudinal void aligns and allows for a continuous void for uninterrupted wire and pipe installation, whether going up and around the door opening or down and into the concrete floor, and the wires go down the utility channel and into the floor, and then come back up into longitudinal void on other side of opening and into the leveling base panel employing “arcuates” so all wires can be fished through chase in closed walls after doors and windows are installed in an Architecturally Finished Complete Building Envelope System.

FIG. 6 shows a section of a three-component wall system with wall block 6 having dark colored one coat adhesive grout 10 applied to part of the exposed exterior face and architectural thin stone 11 and brick 12 applied to it. On the back interior side the liquid sheetrock 24 is applied.

FIG. 7 is a side view of wall block 6 with liquid sheetrock 24 applied to the (left) interior wall and on exterior face (right) the one coat adhesive grout 10 is applied in three thicknesses 13, 14, 15 with thin brick 12 also applied.

FIG. 8 is the same view as FIG. 7 but now with the thin brick 12 applied in the various thicknesses of the one coat adhesive grout 10 with the result being an unanticipated and unique one step instantaneous architectural thin brick 12 that with the use of a finishing tool, the grout lines are tooled to the desired corresponding depth or left oozing as an alternative architectural feature.

FIG. 9 is the architecturally finished cedar shake 10 a horizontal panel that is installed as roof 11 a or wall 12 a. The horizontal wall panel 12 a has lap siding architectural feature 13 a. The seams 14 a are hidden in the underside of the pattern overlap of same thickness “X” and do not require any additional manufacturing or field treatments on the exterior or interior side where liquid sheetrock is applied.

FIG. 11 and FIG. 12 are the mold pans for manufacturing the horizontal architecturally featured panels 11 a, 12 a.

FIG. 9 and FIG. 10 show horizontal applications for the manufacturing of architecturally featured roof 11 a and wall 12 b components. This is a departure from and replacement of the components in the wall CGS, but still works on 2′ CGS with panels that are manufactured architecturally featured top header panel 15 a that includes structural reinforcing and air ducts.

FIG. 11 is a top view of the mold pan 17 that has wire cut patterns 18 passing through the uncured still soft AAC 19. Double-sided mold pattern 22 is held in place by the mold sheets 20 fitting into grooves in the end 22 and the bottom of the mold pan 17. Additionally, the mold sheets are secured by vibrating vertical support rods 23. The all-important attribute of the vibrating vertical support rods 23 is that unlike other molding systems that vibrate the entire mold or insert vibrators into the concrete slurry to remove all the air bubbles and make sure there are no air bubbles on the face of the mold, with AAC, the air bubbles are required and must not be displaced.

The double-sided molds originated in 2004 and system tested and perfected. There is still nothing in the market for AAC, even though others since 2004 have made double sided molds. The incorporation of chemicals that interact with the AAC to help have a bubble free face as well as bond with the future coloring to be added on the site and coating over seam joints 14 a combined with the action of short session, intense small vibrating action of only the molds at the perfect time of curing are what create the surface bubble free, architecturally featured, air insulative, cementitious panels. The vibrating vertical support rods 23 are removed from the AAC after the AAC has cured sufficiently to be self-supportive but still soft enough so it can be cut with industry standard wires 18. After the pan sides are removed, the mold vibrating vertical support rods 23 are removed and the AAC is then wire cut to desired dimensions. The double-sided mold patterns 20 are left in the AAC through the autoclaving process. After the autoclaving process is completed, the AAC is removed from the double-sided mold sheets 20 with result being that the smooth wire cut 18 and pan side 17 faces the interior back side whereon the liquid sheetrock 24 is applied. Another unanticipated advantage is in this unique process of double-sided mold patterns 20 and wire cuts 18 whereby the mold patterns are reversed so when the AAC is removed and flipped over so they can be positioned either horizontally one on top of another shown in FIG. 10 or vertically adjoining each other shown in FIGS. 15, 16, 17 the patterns align and the smooth interior side is able to receive liquid sheetrock 24.

FIG. 13 is the top view of the mold pan 17 and FIG. 14 is the end view of the mold pan 17. All the features of the present invention are the same as for FIG. 12 and FIG. 13 except the double-sided mold sheets 20 are positioned to create vertically aligned components 25 for the walls and roofs.

The various teachings of present invention shown in FIGS. 16, 17, 18 are the way in which the seams 14 are hidden and the pattern perceivably nonreplicating.

FIG. 15 teaches the various featured face of hand split cedar shakes in groups of four that use a unique universal size width shape filler piece 26B that has only slight length and height differences so it fits into molded standard corresponding open space 27 A. This simplifies field installation while assuring no perceivable repeat in the pattern because the adjoining shakes are variably sized molded pieces so that no two look alike. True to the 2′ CGS design, the double sided mold patterns 20 components both horizontal, and vertical can be cut at 2′ sections vertically and horizontally and retain their design and structural integrity.

FIG. 16 teaches a more similar architectural pattern 27 such as uniform cedar shake, Spanish tile, asphalt shingle, slate, etc. on roof 25. The seam 14 a is hidden in this teaching of invention by the pieces where the seam goes through being tooled by either a roller, sponge or the like that has an architectural pattern matching the face of components being joined together. Then the surface is coated in the field.

FIG. 17 shows the vertical wall 25 application of double-sided mold patterns 20.

FIG. 18 teaches monolithic reinforcing cage 30 that has rotating reinforcing shaft 31 with any type of opposite direction twisting or screw type heads 28 and 29.

FIG. 19 teaches round rotating reinforcing shaft 31 that goes through a larger shaft round opening in the monolithic reinforcing cage 30. The round rotating reinforcing shaft 31 has two of any type of opposite direction twisting, low thread revolution screw or cork screw type heads 28 and 29. The securing brackets 29 are attached to the free spinning rotating reinforcing shaft 31 to keep it in place when the spinning rotating reinforcing shaft 31 is inserted into the cementitious architecturally featured panels shown in FIGS. 20, 21 and 22.

In FIG. 20, two cementitious panels with the panel on left 32 being the interior structural panel that will have liquid sheetrock 24 applied to the hidden from the left interior face. The panel on the right is exterior panel 33 that will either have the one coat adhesive grout (FIG. 7, 10) applied or the architecturally featured, insulative, structural panel 13. As shown by the arrows in FIG. 20 the panels will be brought together by machinery in the factory.

In FIG. 21, monolithic reinforcing cage 30 is held in place as the two panels 32 and 33 are brought together. As the two panels contact the monolithic reinforcing cage 30 the rotating reinforcing shafts 31 that have opposite direction twisting or screw type heads 28 and 29 start to spin due to pressure from the panels and in doing so self-drill into the panels 28 with the result being the two panels become permanently attached and monolithic in nature. Then the zero VOC adhesive and structural strength highly insulative foam 34 is poured into the void between the two panels. The result in FIG. 22 is a cementitious fireproof, termite proof, mold proof, nondecaying, zero off gas, highly insulating 34 (R-Value of foam is exponentially compounded when coordinated with AAC thermal values) structural envelope wall that has liquid sheetrock 24 on the interior and architectural features 13 a on the exterior that can be stained during manufacturing and/or colored afterwards to the desired coloration.

FIGS. 23, 24, 26 show air duct 39, crown molding 35 with various components of inside angles 37, outside angles 36, straights 35 and couplings 38.

FIG. 24 shows side view of how the engineer design custom cut in location and size supply vents 40 that connect to the air duct that is enclosed within the architecturally molded, zero VOC, structurally strong, insulative foam.

FIG. 25 shows a top view of a typical path of air duct insulative crown molding.

FIG. 26 is an example of an entire room with an HVAC unit 41.

FIG. 27 is a section of the completed present invention's Architecturally Featured Complete Building Envelope Wall of FIG. 22 that is 10″-14″ thick and teaches how window openings 48 and door openings 47 are cut out of entire wall panels. The required reinforcing required for the opening is either provided by employing top header panel 43 or wherever the architect and engineer specify and opening and required additional reinforcing like a header the trough 44 is cut out. Rebar 45 is added and then high strength concrete 46 is poured into the trough with the result being a cast in place header created that can be made per engineer specifications in width, depth, amount of rebar, etc. The waste product of openings 47, 48 can be ground up and used as soil enhancer 14.

The teachings of the present various required inventions result in a super energy efficient insulated, fireproof, termite proof, mold proof, nondecaying, low embodied energy, healthy habitat that provides better pay and benefits to residents and construction workers and helps greatly reduce global warming. The houses have minimum 100+ year life span that can be cut into sections and reused. 

1. A cementitious building comprising a continuous first course elongated and load-bearing leveling base panel which spans the unevenness of a concrete slab and thereby permit immediate construction of subsequent materials.
 2. The building according to claim 1 wherein architectural features are positioned on said building for the purpose of hiding the mortar joint in the architectural design.
 3. The building according to claim 1 wherein said leveling base panel comprises openings, without any negative effect on the leveling benefit.
 4. A continuous cementitious utility chase system which is architecturally finished on three sides and comprises a vertical channel for a continuous, uninterrupted installation of wires and other utilities.
 5. A cementitious building roof panel structure having a smooth finished interior surface and architecturally detailed exterior surface and a curable, liquid base material on the exterior side of said roof panels, when cured, is waterproof, durable, chemical-resistant, and has a high value of vapor permeability. 